Caster assembly suited for use with modular racks

ABSTRACT

A modular, low cost pallet and shelf assembly with one or more removable caster assemblies is disclosed. The caster assemblies each comprise a first member, the first member having one or more first member features disposed to be removably coupled to a corresponding one or more first matching features of a vertical support member of a shelf assembly; a second member, the second member having one or more second member features disposed to be removably coupled to a corresponding one or more second matching features of the vertical support member; and a wheel assembly, coupleable to the first member and the second member. In one embodiment, the caster assembly includes a horizontal member disposed distal from the wheel that interfaces with a securing member to bear at least a portion of the weight of the rack assembly and to stabilize the caster when mounted to the rack assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/169,493, filed Jun. 29, 2005 by Jeffrey Salmanson and Jon R.Dickey and entitled “MODULAR LOW COST SHELF ASSEMBLY,” now issued asU.S. Pat. No. X,XXX,XXX, which application is a continuation of U.S.patent application Ser. No. 10/772,048, filed Feb. 4, 2004 by JeffreySalmanson and Jon R. Dickey and entitled “MODULAR LOW COST SHELFASSEMBLY”, and issued Aug. 9, 2005 as U.S. Pat. No. 6,925,943, which isa continuation of U.S. patent application Ser. No. 10/388,860, filedMar. 14, 2003 by Jeffrey Salmanson and Jon R. Dickey and entitled“MODULAR LOW COST SHELF ASSEMBLY” and now issued as U.S. Pat. No.6,722,292, which application is a continuation of U.S. patentapplication Ser. No. 09/829,589, filed Apr. 9, 2001, for “MODULAR LOWCOST PALLET AND SHELF ASSEMBLY,” by Jeffrey Salmanson and Jon R. Dickeynow issued as U.S. Pat. No. 6,609,466, which is a continuation of U.S.patent application Ser. No. 09/358,285, filed Jul. 21, 1999, for“MODULAR LOW COST PALLET AND SHELF ASSEMBLY,” by Jeffrey Salmanson andJon R. Dickey, now issued as U.S. Pat. No. 6,244,194, which is acontinuation of application Ser. No. 09/081,411, filed May 19, 1998, for“MODULAR LOW COST PALLET AND SHELF ASSEMBLY,” by Jeffrey Salmanson andJon R. Dickey, now U.S. Pat. No. 5,979,338, issued Nov. 9, 1999, whichclaim benefit of U.S. Provisional Application No. 60/046,883, filed May23, 1997 by Jeffrey Salmanson and Jon R. Dickey, and entitled “MODULARPALLET AND SHELF ASSEMBLY USING CONVENTIONAL HARDWARE,” and U.S.Provisional Application No. 60/062,754, filed Oct. 23, 1997 by JeffreySalmanson and Jon R. Dickey, and entitled “MODULAR LOW COST SHELFASSEMBLY,” all of which applications are hereby incorporated byreference herein.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates generally to shipping and retail displaydevices and more particularly to a modular low cost pallet and shelfassembly using conventional hardware and for removable casters for usewith same.

2. Description of Related Art

Products shipped from the manufacturer or producer are often shipped tothe retailers in corrugated boxes. Typically, these boxes are loadedonto wooden pallets, lifted with a forklift onto a shipping container,and unloaded into the container for transportation to the retail outlet.When the goods arrive at the retail outlet, the corrugated boxes areremoved from the shipping container, loaded onto pallets, moved to theretail display location or storage using a forklift or similar device.The products are then removed from the corrugated boxes, and placed onretail display.

There are several problems associated with the aforementionedprocedures. Unloading and loading the corrugated boxes is alabor-intensive procedure, often resulting in damage to the productsand/or the corrugated boxes. It is also common for the products to bedamaged when the corrugated boxes (which are typically stacked duringstorage and transportation) collapse.

Another problem with these procedures is that the corrugated boxes arenot generally reusable, and must be broken down and disposed of by theretail outlets. Alternative wood racking systems, such as those employedin nurseries, do not solve this problem. These racking systems are alsodifficult to transport, require labor intensive procedures to unloadtransported products and display them at a retail level, and cannot bebroken down easily at the retail outlet. These devices are alsotypically held together with nails, which further complicate theirdisassembly and storage, and make any return to the manufacturergenerally unprofitable.

SUMMARY OF THE INVENTION

As the foregoing indicates, there is a need for efficient transportationof products from the manufacturer or producer to retail display. Thepresent invention satisfies that need.

The present invention discloses a racking system using a modular palletand shelving assembly. This racking system is easily constructed andbroken down, and which uses conventional, standardized, and readilyavailable hardware. The design of the present invention directs theweight of the rack to a metal structure advantageously placed inrelation to the pallet. Even when used with a commonly available woodenpallet, this design is exceptionally strong, allowing the unit to belifted and transported with a forklift or pallet jack. This systemprovides an efficient system for delivering material and products to themarketplace (or to warehouses for later retail sales) without damage.The present invention also allows material and products to be removedfrom trucks by forklift, and placed directly on retail display.

Because the present system also utilizes reusable metal shelving, it canbe easily broken down. This allows the system to be reused on site,disposed of by selling the racking system as a complete package, or inits component parts, or simply returned to the shipper or manufacturerfor re-use. Further, because the design of the present invention is bothsimple and strong, the system can be more space efficiently constructedto take advantage of the available truck container space.

The present invention also can be used with a caster assembly that canbe removably attached to the modular rack assembly to permit wheelingthe rack assembly about. The caster assembly comprises a first memberhaving one or more first member features disposed to be removablycoupled to a corresponding one or more first matching features of avertical support member of the shelf assembly, a second member havingone or more second member features disposed to be removably coupled to acorresponding one or more second matching features of the verticalsupport member; and a wheel assembly, coupleable to the first member andthe second member.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings in which like reference numbers representcorresponding parts throughout:

FIG. 1 is a perspective view of the one embodiment of the presentinvention;

FIG. 2A is a view of one embodiment of the present invention,illustrating a coupling between the pallet and the shelving;

FIG. 2B is a close up view of the relationship between the tabs and thekeyhole apertures in one embodiment of the present invention;

FIG. 3 is a side view of one embodiment of the present invention,illustrating the pallet and vertical support members;

FIG. 4 is a perspective view of an embodiment of the present inventionusing cleats;

FIG. 5 is a close up view of one embodiment of the present invention,illustrating a coupling between the pallet and vertical support members;

FIG. 6 is a side view of one embodiment of the present invention,illustrating the use of cleats to couple the pallet and the verticalsupport members;

FIG. 7 is a diagram of the cleats used in one embodiment of the presentinvention;

FIG. 8A is a perspective view of another embodiment of the presentinvention illustrating a segmented design suitable for smallermerchandising units;

FIG. 8B is a section view of the coupling between the segments shown inFIG. 8A;

FIG. 9A presents a side view illustrating the use of an inverted keyholeaperture configuration;

FIG. 9B presents a top view illustrating the use of an inverted keyholeaperture configuration;

FIG. 10 is a perspective view of an embodiment using the invertedkeyhole aperture configuration;

FIG. 11 is a top view of another embodiment of the present inventionusing the inverted keyhole apertures;

FIG. 12A is a top view of another embodiment of the present inventionshowing an alternative arrangement for the pallet securing members;

FIG. 12B is a side view of another embodiment of the present inventionshowing an alternative arrangement for the pallet securing members;

FIG. 13 is a perspective view of another embodiment of the presentinvention showing an alternative arrangement for the pallet securingmembers;

FIG. 14 is a side view of another embodiment of the present inventionshowing the use of double-sided keyhole apertures;

FIG. 15 is a side view of another embodiment of the present inventionshowing the use of a strengthening segment in the vertical supportmember;

FIG. 16 is a side view of another embodiment of the present inventionshowing the use of fewer keyhole apertures;

FIG. 17 is a flow chart depicting the assembly of one embodiment of thepresent invention;

FIGS. 18A-18F are diagrams of embodiments of a caster assembly that canbe removably attached to one or more of the vertical support members ofthe rack assembly;

FIGS. 19A-19C are diagrams showing an alternative embodiment of how thecaster assembly may be coupled to the vertical support members of therack assembly;

FIG. 19D-19F are diagrams showing an alternative trimmed tab embodiment;

FIG. 19G-19I are diagrams showing how the caster assembly can beattached to the vertical support members using the trimmed tabembodiment;

FIG. 20 is a flow chart describing exemplary method steps that can beused to assemble a shelf assembly with casters;

FIG. 21 is a diagram showing one embodiment of the caster assemblycoupled to the rack assembly; and

FIG. 22 is a diagram showing a second embodiment of the caster assemblycoupled to the rack assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the following description of the preferred embodiment, reference ismade to the accompanying drawings which form a part hereof, and in whichis shown by way of illustration a specific embodiment in which theinvention may be practiced. It is understood that other embodiments maybe utilized and structural changes may be made without departing fromthe scope of the present invention.

FIG. 1 is a perspective view of one embodiment of the present invention.The invention comprises a plurality of L-shaped vertical support members100, which are so arranged to accept a pallet 102 therebetween. In oneembodiment, the pallet 102 is a common two-way wood pallet, whichaccepts forklift tongues in slots on the front and rear of the pallet102. In an alternative embodiment, a four-way pallet may be used. Thefour-way pallet comprises additional slots to on opposite sides of thepallet to accept forklift tongues, thus allowing the pallet to be liftedby a forklift from any side. The design of the pallet 102 can be changedto accommodate different loads, with heavier-duty construction pallets102 employed for maximum strength applications. Each vertical supportmember 100 comprises a plurality of keyhole shaped apertures 108disposed on the right angle portions of the vertical support members100. In one embodiment, the vertical support members 100 are commonlyavailable angle posts that are 84 inches in length.

The present invention also comprises a plurality of L-shaped crossbraces 104, which are affixed to the vertical support members 100. EachL-shaped cross brace 104 comprises a right angle portion and a number ofcross brace tabs 109, each of which is small enough to be inserted intothe larger portion of the keyhole shaped aperture 108, yet large enoughto be retained by the smaller portion of the keyhole shaped aperture108. When a plurality of braces 104 are so coupled with the verticalcross members 100, the right angle portion (which comprises the lowerportion of and “L” when viewed from the side) of the brace 104 forms ahorizontal surface, upon which a planar surface 106 is placed. Planarsurface 106 is sized so as to be inserted between all four verticalsupport members 100 and larger than the aperture formed by the braces104 extending between the vertical support members. Accordingly, thebraces 104 serve to support the planar surface 106. The planar surface106 can be comprised of particle board, OSB, plastic, metal, or othermaterial. Planar surface 106 may also be molded to conform to theproduct.

In one embodiment, the braces 104 are commonly available double rivetbeams. The size of the braces 104 is selected in accordance with thedesired dimensions of the finished assembly, as is the pallet 102 size.In a typical arrangement, two of the braces 104 are 48 inches in length,and two are 42 inches in length. The number of braces 104 used in theassembly is also determined by the number of desired shelves of thefinished product. For example, a four-shelf unit would require eight 48inch braces 104 and eight 42 inch braces, whereas a five-shelf unit woodrequire ten 48 inch braces and ten 42 inch braces.

Since four braces 104 are not required to hold the planar surfaces 106,it is also possible to use only two braces per shelf level, in astaggered relationship. For example, the first level can use two 48 inchbraces 104, the next, two 42 inch braces 104, and so on. Thisconfiguration is nominally not as strong, but is lower in cost, andsuitable for many applications.

FIG. 2A is a close up view of one embodiment of the present invention,illustrating the relationship between the pallet 102 and the verticalsupport members 100. In this embodiment, pallet securing members 118 areutilized to releasably accept and secure the pallet 102 in place betweenthe vertical support members 100, and to bear the weight of the rackingsystem when lifted by a fork lift or pallet jack. As strength requires,either two or four pallet-securing members 118 can be used.

FIG. 2B is a detailed view of the embodiment shown in FIG. 2. Keyholeapertures 108 each comprise a first aperture segment 107 and a secondaperture segment 109, which is smaller in cross section than the firstaperture segment 107. Tab heads 110A are smaller than the first aperturesegment 107, yet larger than the second aperture segment 109. Hence,when tab heads 110A are inserted into the first aperture segment 107 andmoved laterally, the tab 110 is affixed within the aperture 108.

The pallet 102 comprises a plurality of bottom members 112 and supportmembers 114, both of which are affixed to a pallet cross member 116. Inone embodiment, the vertical support members 100 are affixed to thepallet 102 by inserting one or more wood screws 124 (such as lag screws)of suitable length and diametric cross section through the appropriatekeyhole apertures 108 and into the pallet 102.

In another embodiment, a number of pallet-securing members 118 areemployed. These pallet-securing members 118 comprise one or morepallet-securing member tabs 110 which are inserted into the keyholeapertures 108 of the vertical support members 100. Ordinarily, thepallet-securing member tabs 110 are of the same design as the crossmember tabs 109. However, since the pallet-securing member tabs 110 mustbear greater weight and shear force, these tabs may be suitablyreinforced or made of stronger material, if necessary.

In one embodiment, the pallet-securing members 118 are cross braces 104but inverted so that an interiorly-extending portion 120 having ahorizontal surface is disposed above the vertical surface 122. Thisplaces an interiorly-extending securing surface 120 over the top of thepallet 102, and in particular, the support members 114. In thisconfiguration, the pallet 102 is restrained between the vertical supportmembers 100. Pallet securing member tabs 110 on the support members 118are inserted into the larger opening of the keyhole tabs 108. Thesupport members 118 transfer the weight of the assembly to the metalstructure, rather than the pallet 102.

The pallet support members 118 and vertical support members 100 mayoptionally be affixed to the pallet 102 with a suitably sized fasteningdevice 124 such as a wood screw or lag bolt. The fastening device 124should comprise a head larger than any dimension of the keyhole aperture108. This assures that the components are securely fastened together.One-quarter inch lag bolts of 1¼ inch length are suitable for thispurpose. If necessary, a suitably placed hole or aperture may be drilledthrough the pallet 102 before the bolt is inserted and thereaftersecured with a nut or other means.

The tabs 110 comprise a head portion 110A and a shank portion 110B. Thehead 110A is a smaller diameter than the larger portion of the keyholeapertures 108, to allow insertion therein. In one embodiment, the upperportion of the inner surface of the keyhole aperture 108 and the tabshank 110B are in contact, thus causing the tab head 110A to extendbeyond the keyhole aperture 108. This provides additional strength toprevent the vertical support members 100 from extending away from thesupport brace 118. In another embodiment, the head size of the fasteningdevice 124 is selected to be close to or contact the tab to minimizethis possibility. In still another embodiment, the support brace 118comprises two or more tabs 110, and each tab is inserted into itscorresponding keyhole aperture 108. For additional strength, all ofthese couplings may be further secured by additional fastening devices124, if desired.

FIG. 3 is a front view of one embodiment of the invention showinganother view of the coupling between the pallet and vertical supportmembers.

FIG. 4 presents another embodiment of the present invention, wherepallet securing members 118 comprise one or more cleats 126, including aleft cleat 126A and a right cleat 126B.

FIG. 5 presents a close-up view of an embodiment of the modular palletassembly in which the pallet securing member 118 is embodied in one ormore cleats 126. Nominally, each cleat 126 is L-shaped, and comprises aone or more cleat tabs 111 on one outer surface, and one or morekeyhole-shaped apertures 108 on the other outer surface. The cleat 126also includes an interiorly-extending securing surface over the pallet102. In one embodiment, the cleat 126 is affixed to the pallet 102 byone or more fastening devices 128 inserted through the keyhole aperture108 in the cleat. The fastening device 128 can be a wood screw ofsuitable dimension or other fastening means. Optionally, verticalsupport member 100 can be further secured to the pallet by one or moreadditional fastening devices 130. Cleat tab 111 extends within a keyholeaperture 108, and may be secured with an additional fastening device asdescribed herein.

FIG. 6 is a side view of the embodiment shown in FIGS. 4 and 5.

FIG. 7 is an illustration showing the two types of cleats employed inthe embodiments shown in FIGS. 4 and 5. Left cleats 126A (depicted inFIG. 5), and right cleats 126B are employed. Nominally, a total of fourcleats 126 (two left cleats 126A, and two right cleats 126B) are used.

Nominally, four vertical support members 100 are employed in the presentinvention, one at each corner of the pallet 102. In alternativeembodiments, the present invention can comprise additional verticalsupport members 100 for additional bracing. Nominally, these additionalvertical support members 100 will be flat, and not L-shaped, so as to beeasily affixed to the cross members 104, but the present invention canaccommodate a wide variety of vertical support member shapes withmodification. These additional vertical support members 100 may beaffixed to the pallet, but need not be so. Further, if exceptionalrigidity is required, the additional cross bracing may be employed ineither the pallet 102 structure, the metal between vertical supportmembers 100, or both.

FIG. 8A presents perspective view of another embodiment of the presentinvention illustrating a segmented design in which the assemblycomprises two rigid, yet easily separable sections which can beseparated to form smaller shelving units for separate transport or fordisplay and merchandising of products. In this embodiment, the verticalsupport members 100 comprise bottom vertical support members 100A andtop vertical support members 100B, both of which are of generallyshorter length than the vertical support members 100 previouslydescribed herein. The lower portion of the bottom vertical supportmembers 100A are secured to a first pallet 102A using the techniques andstructures described earlier in this disclosure.

A plurality of cross braces 104 are coupled to the vertical supportmembers 100. Cross braces 104A are coupled to the vertical supportmembers 100 to form an aperture for inserting planar surfaces 106 aright angle shelf portion on which supports the planar surfaces 106, aspreviously described and illustrated. Pallet support members 105 areinserted between the lower vertical support members 100A at the topmostposition in an inverted “L” configuration, with the right angle portiondisposed above or below the vertical portion. So disposed, the rightangle portions of the pallet support members 104B form a shelf or cavitywhich supports a second pallet 102B, which, if desired, may be securedto the assembly using lag screws 130 or similar fastening devicesinserted through apertures in the right angle portions of the crossbraces 104B. Upper vertical support members 100B and second palletsecuring members such as the cleats 126 described earlier are thensecured to the upper pallet 102B using the structures and methodspreviously described to secure the shelving to the pallet 102, usingeither cleats 126, pallet securing members 118, or inverted cross braces104.

FIG. 8B is a side view of the structures shown in FIG. 8A.

FIG. 9A presents a side view of another embodiment of the presentinvention illustrating the use of a unique keyhole aperture 108configuration. In this embodiment, the vertical support member 100comprises two sets of keyhole apertures 108, a first set 121 comprisingone or more keyhole apertures 108A facing in a first direction, and asecond set 123 comprising one or more keyhole apertures 108B facing in asecond direction substantially inverted from that of the first set ofkeyhole apertures 108A. For purposes of clarity, keyhole apertures 108Awill be referred to henceforth as downward facing keyhole apertures, andkeyhole apertures 108B will be referred to as upward facing keyholeapertures. This embodiment also shows another alternative for the palletsecuring members 118. Here, one or more right angle support members 140,having one or more right angle support member tabs 113 of suitable sizefor insertion into the upward facing keyhole apertures 108B areutilized. The right angle support members 140 are disposed adjacent tothe vertical support members 100 in a fitting relationship and affixedto the vertical support members by inserting tabs 113 in the upwardfacing keyhole apertures 108B, and applying suitable force in adirection towards the upward facing keyhole aperture 108B smallerportion.

When the foregoing elements are arranged as described above, a pallet102 can be inserted in the space formed by the vertical support members100 to allow the entire assembly to be lifted and moved with a forkliftor other similar device. Lifting forces from the pallet 102 are thenborne by the right angle support members 140, right angle support membertabs 113, and upward facing keyhole aperture 118B smaller portions,structural elements which are well suited to support considerableweight. This embodiment may also be practiced with the use of palletsecuring members 118 or cleats 126 in the place of right angle supportmember 140. This embodiment also obviates the need for the insertion orremoval of pallet securing devices 124, speeding assembly anddisassembly.

FIG. 9B is a top view of the embodiments shown in FIG. 9A.

FIG. 10 shows a perspective view of the foregoing embodiment of thepresent invention. Safety devices, such as clips or right angle bolts142 can be inserted into keyhole apertures 108. In the event of a tab110 failure, these safety devices serve to restrict excessive motion ofstructures that were supported by the failed tab 110. In the illustratedembodiment, right angle bolt 142 is inserted into keyhole aperture 108A.The right angle bolt 142 comprises a head structure 144 which preventspassage through the keyhole aperture 108, and preferably, a shankstructure 146 that is smaller in cross section than the smaller portionof the keyhole aperture 108. In one embodiment, shank structure 146 isof sufficient length and/or mass to assure that the right angle bolt 142is balanced to as to remain in the keyhole aperture 108 after insertion.If necessary, the safety device may be locked or secured into thekeyhole apertures by bolts, clips, pins, or other means.

Friction between the tabs 110 and the upward facing keyhole apertures108B as well as friction between the right angle support members 140 andthe vertical support members 100 are generally sufficient to retain thetabs 113 in the smaller portion of the keyhole aperture 108B. However,if desired, vertical support member 100 and right angle support member140 may also comprise interconnecting fastening means. Such fasteningmeans can feature, for example, one or more shear apertures 150 in eachstructure adjacently disposed on assembly, thus allowing the insertionof a pin, nail, or other device 152 after assembly to restrict theapertures from sliding relative to one another. Similarly, if desired,the right angle support member 140 and pallet 102 can be affirmativelysecured to the vertical support member 100 by means of a wood screw,nail, bolt or other securing device 144 inserted through the upwardfacing keyhole aperture 108B larger portion.

FIG. 11 is a diagram illustrating another embodiment of the presentinvention. In this embodiment, a simple cleat 126 is used in place ofthe right angle support member 126. If additional strength is desired, asecond cleat can be disposed at a right angle to and lapped on top ofthe illustrated cleat so that the cleat tabs 111 from the second cleatare disposed through the upward facing keyhole apertures 108A in thevertical support member 100. If necessary, the location of the upwardfacing keyhole apertures 108A presented to the cleat tabs 111 of thesecond cleat can be adjusted vertically in an amount sufficient toaccount for the vertical displacement of the second cleat, or thelocation of the tabs on the second cleat can be so adjusted to achievethe same effect. Also, if desired, a nail, bolt, or wood screw may beinserted into the cleat 126 keyhole aperture 118 and into the pallet 102to secure the pallet 102 to the assembly.

Upward facing keyhole apertures 108B are generally disposed near thelower portion of the vertical support members 100. However, that neednot be the case. Upward facing keyhole apertures 108B can be disposed onany portion of the vertical support members 100, and when used inconjunction with other structures herein described, provide anexceptionally strong means for lifting and transporting any assemblyconstructed using the vertical support members 100.

FIGS. 12A and 12B present another embodiment of the present invention,in which the pallet securing members 118 (here, inverted cross braces104) are affixed so that the securing surface is disposed at the bottomof the securing member. This configuration can be advantageously used toaccommodate different pallet 102 thicknesses.

FIG. 13 is a perspective view of the alternative embodiment shown inFIGS. 12A and 12B.

FIG. 14 is a side view of another embodiment of the present invention inwhich keyhole apertures are replaced with double-sided keyhole apertures200. Each double-sided keyhole aperture 200 has an upward orientedaperture segment 202 and a downward oriented aperture segment 204. Thisdesign is simpler to produce because the keyhole apertures 200 have asymmetrical orientation and can be easily punched from the verticalsupport members 100 without reorientation.

FIG. 15 illustrates another embodiment of the present invention usingdouble-sided keyhole apertures 200. In this embodiment, a strengtheningsegment 220 is placed between the double-sided keyhole apertures 200 toincrease the strength of the modular shelving. This configuration isparticularly well suited to heavy loads. Strengthening segment 220 canbe implemented by a greater distance between double-sided keyholeapertures 222 and 224, a greater distance between the double-sidedkeyhole apertures 224 and 226, or a greater distance between both.Alternatively, a vertical support member can be reinforced in this areas required with additional thickness material, molding or stamping astronger shape, or by heat treatment

FIG. 16 illustrates another embodiment of the present invention in whichonly a limited number of double-sided keyhole apertures 200 areutilized. This configuration is useful in situations where highervertical support member 100 rigidity is required, or when lessflexibility in shelf location is required.

In addition to the aforementioned advantages, the present invention isalso easily constructed and broken down. Construction is accomplished byplacing pallet securing members 118 or cleats 128 about the periphery ofthe pallet 102 so that the pallet securing tabs 110 (or, in embodimentsusing cleats 126, the cleat tabs 111) face outward from the center ofthe pallet. Next, vertical support members 100 are placed at each cornerof the pallet 102. Then, downward force is applied to the verticalsupport members to lock them to the pallet securing members 118 (orcleats 126). Then, the desired number of number and location of shelvesis determined. At the aforementioned locations, four cross braces 104are inserted into the structure with the tabs 110 on the braces fittinginto the keyhole apertures 108 in the vertical support members 100.Downward force is then applied to the cross braces 104, affixing them inposition. When so inserted, these cross braces 104 form a shelf uponwhich the planar surface 106 is placed, completing the construction.Disassembly follows the reverse procedure.

FIG. 17 is a flowchart illustrating the foregoing operations. Theprocess begins by placing 302 a pallet securing member 118 having apallet securing tab 110 about the periphery of a pallet so that thepallet securing tab faces outward from the center of the pallet 102.Then, vertical support members 100 are placed 304 at each corner of thepallet 102, and the pallet securing tabs 110 are inserted 306 throughthe keyhole apertures 108. Pressure is then applied 308 to each verticalsupport member 100 so as to affix the keyhole apertures 108 to thepallet securing tabs 110. A plurality of cross braces 104 having crossbrace tabs 109 are then disposed 310 between the vertical supportmembers 100. These cross braces 104 are then coupled and secured to thevertical support members 100 by inserting the cross member tabs 109 inthe vertical support member apertures 108 and applying suitable force onthe cross member braces 104. Finally, the process is completed byplacing 316 shelving between the vertical support members 100 and uponthe cross member braces 104.

The present invention may be practiced in a number of embodiments. Forexample, while the foregoing has been described with respect toconventional L-shaped steel shelving with tabs 110 and keyhole shapedapertures 108, the present invention can be practiced with other meansto affix the elements of the invention together. Similarly, althoughgenerally stronger in construction, L-shaped members are not required topractice the present invention. Although the present invention isespecially suitable for transport via fork lifts, it is also envisionedthat the foregoing invention can be practiced with the use of wheels(which may comprise braking or setting means) affixed to the bottomsurface of the pallet 102. Also, while the present invention has beendescribed with apertures 108 on the vertical support members 100, andtabs on other elements, the invention is not so limited, and could bepracticed in other embodiments. For example, the present invention couldbe practiced using tabs on the vertical support members, and apertureson the other interconnecting elements. Cross braces can also be affixedwith the use of push-through sections at appropriate locations in thevertical support members. Such push through sections can be fashioned bymaking U-shaped cuts in the vertical support members, and bending thecut sections inward. The upper portion of the cut sections can thensupport cross braces or shelving of medium to light weight.

Wheeled Embodiments

FIGS. 18A-18C are diagrams showing a caster assembly 1802 that can beremovably attached to one or more of the vertical support members 100.FIG. 18A is a diagram showing a top view of the caster assembly 1802,FIG. 18B is a drawing showing a bottom view of the caster assembly, andFIG. 18C is a diagram showing a bottom view of the caster assembly 1802and a coupleable wheel assembly 1822. In FIGS. 18A-18C, an arrow isshown, delineating the observer's perspective for the other views shown.For example, the “C” arrows of FIGS. 18A and 18B illustrate thedirection an observer would be viewing the caster assembly 1802 to seethe side view presented in FIG. 18C. Also, the “A” and “B” arrows shownin FIG. 18C indicate the direction an observer would be viewing thecaster assembly 1802 to see the top and bottom views of FIGS. 18A and18B, respectively.

The caster assembly 1802 can be removably coupled to the lower extremityof the vertical support members 100 and are configured for attachment ofwheels, thus permitting wheels to be attached to the modular shelfassembly so that it may be wheeled about.

In the embodiment shown in FIGS. 18A-18C, the caster assembly 1802comprises a first member 1804 and a second member 1806 communicativelycoupled to the first member 1804. In the illustrated embodiment, thefirst member 1804 and the second member 1806 are planar members, and aredisposed perpendicular to one another so that they may be inserted intothe concave portion of the “L” shaped vertical support members 100.However, all that is required is that the first member 1804 and thesecond member 1806 together form an outside surface shaped tosubstantially conform to that of the inner surface of the verticalsupport member 100. For example, the interior surface of one or more ofthe vertical support members 100 could be “V” shaped or even planar, inwhich case, the caster assembly 1802 would be shaped to conform to suchsurface.

In the illustrated embodiment, the caster assembly 1802 comprises asleeve 1810, sized and shaped to accept a shaft portion 1824 of a wheelassembly 1822 as further described below. The first member 1804 and thesecond member 1806 may also be coupled to one another via the sleeve1810. That is, instead of or in addition to the first member 1804 beingwelded or otherwise affixed to the second member 1806 at the edges ofthe members 1804,1806, the first member 1804 and the second member 1806can be affixed to each other via the sleeve 1810 (e.g. by affixing bothto the sleeve 1810 but not to each other).

Preferably, the caster assembly 1802 also comprises a third member 1808which is disposed on an opposite end of the caster assembly 1802 fromthe wheel assembly 1822 and perpendicularly to the first member 1804 andthe second member 1806. As is shown below, when the caster assembly 1802is installed in the vertical support member 100 of the modular rackassembly, the third member 1808 is disposed proximate (and typicallyadjacent to and in contact with) and parallel to the downward-facingsecuring surface 120 of the modular shelf assembly described above. Thethird member 1808 interfaces with this downward facing securing surface120, allowing that surface to support at least a portion of the weightof the modular shelf assembly when the modular shelf assembly is wheeledabout.

The third member 1808 is shown in FIGS. 18A-18C as extending from thefirst member 1804 to the second member 1806 and coupled to both (e.g.via welding), but this need not be the case.

FIGS. 18D and 18E illustrate further embodiments of the caster assembly1802, in showing different third member 1808 designs. In FIG. 8D, thecaster assembly includes two third members 1808′ which provide surfacesextending perpendicularly from the first member 1804 towards the convex(or interior) area of the caster assembly 1804. Such third members 1808′can be formed by simply stamping a form for the first member 1804 thatincludes a suitably sized and shaped surface, and bending this surfaceover to be perpendicular to the first member 1804. FIG. 18E shows asimilar embodiment, except the third members 1808″ extend to the sleeve1810. This strengthens the caster assembly 1802, by using the presenceof the sleeve 1810 to prevent the third member 1808″ from being bentfurther downwards with the application of weight to the third member1808″.

The first member 1804 and second member 1806 each include one or morefeatures which are disposed and configured to be removably coupled to acorresponding one or more features of the vertical support member 100.In the embodiments illustrated in FIGS. 18A-18C, these first membersurface features comprise a pair of tabs 1812A,B on the first member1804 and the second member surface features comprise a pair of tabs1814A,B on the second member 1806. These tabs 1812A,B and 1814A,B areinserted into corresponding features (such as the double-sided keyholeapertures 200 described above) in the corresponding vertical supportmember 100 and the caster assembly 1802 is slid upwards to affix thecaster assembly 1802 to the vertical support member 100.

FIGS. 18A-18C also disclose optional sub-members 1816, 1818 which aredisposed at the wheel end of the caster assembly 1802. The sub-members1816, 1818 provide additional support to allow the caster assembly 1802to support the weight of the modular shelf assembly. The sub-members1816, 1818 extend away from the concave portion of the caster assembly(i.e. outwards), and are disposed on the edge of the caster assembly1802. When the caster assembly 1802 is affixed to the vertical supportmember 100, the sub-members 1816, 1818 extend under the bottom of thevertical support members 100 and accept at least a portion of the weightof the modular rack assembly. These sub-members 1816, 1818 also reducetorquing of members 100 during the transport of the rack under load bygrasping the corner post at it's bottom, where twisting or torquing isat is maximum when the rack is rolled about under load.

The sub-members 1816, 1818 can be simply extensions that present ahorizontal surface perpendicular to and below the bottom end of thevertical support member 100 (as shown in FIGS. 18D-18F), or, they maycomprise “J” or “hook” cross-sectioned extensions that reach under andto the outside surface of the vertical support member 100. In eithercase, the sub-members 1816-1818 can be formed by suitable stamping theshape of the first and second members 1804, 1806 to include a featureand bending the feature in the appropriate direction.

In sub-members 1816, 1818 can substantially increase the strength andstability of the attachment of the caster assembly 1802 to the verticalsupport members 100. In one embodiment, the sub-members 1816, 1818 areof sufficient size and strength and are disposed such that two tabs(e.g. 1812A and 1814A) can be eliminated. This makes insertion of theremaining tabs (e.g. 1812B and 1814B) into the apertures 200 easier toaccomplish.

The foregoing structures (e.g. tabs 1812A,B and 1814A,B inserted withinand affixed to corresponding apertures 200 in the vertical supportmember 100, a third member 1808 interfacing with this downward facingsecuring surface 120, and sub-members 1816 and 1818) provide for anextremely strong and secure attachment of the caster/wheel assembly tothe rack assembly.

In one embodiment, the wheel assembly 1822 and caster assembly 1902comprise interacting structures to which retain the shaft portion 1824within the sleeve 1810, thus preventing the shaft portion from fallingout of the sleeve should one of the wheel assemblies 1822 pass over abump or a curb. In one embodiment, these interacting structures comprisea compressible ring 1850 and a matching notch 1852.

It is noted that the size, shape, and location of the apertures 200 maybe modified to more easily permit the caster assembly 1802 to beattached. For example, FIGS. 19A-19C illustrate an embodiment in whichselected apertures 200 of the vertical support members 100 are modifiedto permit easier insertion of the tabs 1812, 1814 of the caster assembly1802.

FIG. 19A illustrates an aperture 1902 in which the vertical portion 200′is offset by a distance “d” from the nominal position (the distance “d”being the approximate distance from the top of the head to the base oftab 1814). This allows insertion of tab 1812 into the aperture 200′, thesliding the caster assembly 1802 to the position illustrated in FIG. 19B(thus disposing the tab 1814 through aperture 200, and sliding thecaster assembly upwards locking the first tab 1812 in aperture 1902 andthe second tab 1814 in the second aperture 200 as shown in FIG. 19C.Also note that when the caster assembly 1802 is slid upwards, thesub-member 1818 interfaces with the vertical support member 110. In theflat tab embodiment disclosed in FIG. 18F, the sub-member 1818 providesadditional weight-bearing capability, while in the hooked embodiment ofthe sub-member shown in FIG. 18C, both weight bearing and enhancedstability are provided, as the sub-member 1818 prevents shifting thecaster assembly 1802 away from the longitudinal axis of the verticalsupport member.

While FIGS. 19A-19C depict a system wherein the apertures 200 aremodified in order that the caster assembly 1802 can be easily coupled tothe vertical support members 100, this can also be accomplished bymodifying the tabs 1802.

FIGS. 19D-19F are top, side, and perspective views of an alternateembodiment of the tabs 1812 (denoted 1812′). The tabs 1812 include ahead portion base portion 1904, a center portion 1906 and a head portion1908. In the embodiment illustrated in FIGS. 19D-19F, the head portionis trimmed so that less than the full circumference of the head ispresent.

FIGS. 19G-19I are drawings depicting how the tabs 1812′ having trimmedheads are facilitate assembly of the caster assembly 1802 on the rack.FIG. 19G depicts insertion of the trimmed tab 1812′ into a standarddouble sided keyhole aperture 200. Because the tab 1812′ is trimmed, itcan be inserted into it's respective aperture while tab 1814 remains outof it's aperture. Then, as shown in FIG. 19H, the caster assembly 1802can be slid to the left, placing tab 1814 in its aperture as well.Sliding the caster assembly 1802 upward then removably affixes thecaster assembly 1802 to the vertical support member 100 via both tabs(1814 and 1812′) and by structure 1818. Note that the circumferentiallytrimmed head of the tab 1812 allow the insertion of the that tab 1812′into its respective aperture 200 while also allowing a orthogonallydisposed tab 1814 to be inserted into another respective aperture 200.

Other attaching features can be used to removably affix the casterassembly 1802 to the vertical support member 100. For example, mutuallycooperative tabs may be placed in the vertical support member, andapertures in the caster assembly. Further, the vertical support member100 may have a tab and an aperture, while the caster assembly 1802 alsohas corresponding apertures and tabs, respectively. While tabs andcooperatively interlocking tabs are a preferred embodiment of thepresent invention, the present invention could also be implemented withother attachment structures.

FIG. 20 is a flow chart describing exemplary method steps that can beused to assemble a shelf assembly with casters. The assembly process ofFIG. 20 will be described in conjunction with FIG. 21, which presents anembodiment of the caster assembly 1802 assembled on a modular rackassembly.

As shown in block 2002, a caster assembly 1802 is removably affixed to abottom end of each of the vertical support members 100. The casterassembly 1802 comprises a caster assembly 1802 that includes a firstmember (e.g. 1804 or 1806) which is disposed to accept a wheel 1826,disposed on a first end of the first member 1804,1806, and a casterweight bearing member 1808, which has a surface that is perpendicular tothe vertical support member 100 when affixed to the vertical supportmember 100. In one embodiment, the caster assembly 1802 is affixed tothe vertical support member 100 by inserting tabs 1812, 1814 intomatching apertures 200 in the vertical support member 100, and applyingforce to the caster assembly 1802 in a direction away from the bottom ofthe vertical support member 100 and towards its longitudinal center.

As shown in block 2004, the securing member 118 is then removablyaffixed to at least one of the vertical support members 100. In theembodiment illustrated in FIG. 21, the securing member 118 comprises aninverted cross brace 104 having an inward-extending horizontal weightbearing member 2002 having a downward surface, and is configured to bearat least a portion of the weight of the shelf assembly. When thesecuring member 118 is installed, the downward surface of the horizontalweight bearing member 2002 is disposed proximate (and optionally incontact with) the third member 1808. This interaction limits the motionof the caster assembly 180 after affixment to the vertical supportmembers, thus providing for an attachment to the vertical support member100 with increased stability.

FIG. 22 is a diagram illustrating another embodiment of the casterassembly 1802 in use with the modular rack assembly. As is the case withthe embodiment shown in FIG. 21, when the securing member 118 (asillustrated, inverted cross brace 104) is installed to the verticalsupport member and the caster assembly 1802 is installed thereafter, theweight bearing member 2002 of the securing member 118 is disposedproximate and preferably, in contact with the third surface 1808 of thecaster assembly 1802. Unlike the embodiment shown in FIG. 21, thesecuring member 118 affixed to the vertical support member 100 such thatthe securing member tabs 2202 are at the upper end of the apertures inthe vertical support member (in this respect, similar to the embodimentshown in FIG. 14). This embodiment has several advantages. First, thisembodiment allows easy conversion from a rack that is moved about bylifting the pallet 102 disposed therebelow to a rack that is moved aboutby attachment of the caster assembly 1802. That is because in bothcases, the securing member 118 helps support the weight of the rackassembly as it is moved about. When moved about by the pallet 102, thesecuring member 118 contacts the pallet 102 and prevents the pallet 102from moving upwards and helps bear the weight of the modular rackassembly. When moved about by wheels and the caster assembly 1802, thesecuring member 118 contacts the third surface 1808 and helps bear theweight of the modular rack assembly on the caster assembly 1802.

Conclusion

In summary, a modular pallet and shelving assembly has been describedwhich uses widely available conventional components, reduces damage toproducts in transit, and reduces time consuming handling of products toremove them from shipping containers and place them on retail shelves.The present invention presents a flexible solution to producttransportation. The structure may be returned to the manufacturer,broken down and used for its component parts, or disposed of, orreturned to the manufacturer in an assembled or disassembled state.Further, the present invention supports multiple pallet structures toheights suitable for retail display and merchandising.

The foregoing description of the preferred embodiments of the inventionhas been presented for the purposes of illustration and description. Itis not intended to be exhaustive or to limit the invention to theprecise form disclosed. Many modifications and variations are possiblein light of the above teaching. It is intended that the scope of theinvention be limited not by this detailed description, but rather by theclaims appended hereto. The above specification, examples and dataprovide a complete description of the manufacture and use of thecomposition of the invention. Since many embodiments of the inventioncan be made without departing from the spirit and scope of theinvention, the invention resides in the claims hereinafter appended.

1. A caster assembly, comprising: a first member, the first memberhaving one or more first member features disposed to be removablycoupled to a corresponding one or more first matching features of avertical support member of a shelf assembly; a second member, the secondmember having one or more second member features disposed to beremovably coupled to a corresponding one or more second matchingfeatures of the vertical support member; and a wheel assembly,coupleable to the first member and the second member.
 2. The casterassembly of claim 1, wherein the one or more first member features andthe one or more second member features are tabs and the one or morefirst matching features and the one or more second matching features areapertures.
 3. The caster assembly of claim 2, wherein the apertures arekeyhole apertures are the tabs are disposed and shaped for acceptanceinto keyhole apertures in the vertical support member.
 4. The casterassembly of claim 3, wherein at least one of the tabs includes a headthat is circumferentially trimmed to allow the insertion of the at leastone tab into an aperture while also allowing a orthogonally disposed tabto be inserted into another aperture.
 5. The caster assembly of claim 1,wherein the first member and the second member together form a surfaceshapingly conforming to a surface of the vertical support member.
 6. Thecaster assembly of claim 1, wherein the first member and the secondmember are planar.
 7. The caster assembly of claim 1, wherein the secondmember is perpendicular to the first member.
 8. The caster assembly ofclaim 1, wherein the wheel is removably coupleable to the first memberand the second member.
 9. The caster assembly of claim 1, wherein thewheel assembly comprises a shaft and the wheel assembly is coupleable tothe first member and the second member via insertion of the shaft into asleeve coupled between the first member and the second member.
 10. Thecaster assembly of claim 1, further comprising: a third member, disposedon an opposite end of the caster assembly from the wheel andperpendicular to the first member and the second member.
 11. The casterassembly of claim 10, wherein the third member is disposed adjacent andparallel to a securing surface configured to bear at least a portion ofthe weight of the shelf assembly when the caster is coupled to thevertical support member.
 12. The caster assembly of claim 11, whereinthe securing surface is disposed on a support member removablycoupleable to the vertical support member.
 13. The caster assembly ofclaim 1, wherein: the shelf assembly further comprises a support member,coupled to the vertical support member, the support member having asecuring surface disposable over a pallet and configured to bear atleast a portion of the weight of the shelf assembly when the shelfassembly is lifted by the pallet; and the caster assembly furthercomprises a third surface perpendicular to the first surface and thesecond surface and disposed adjacent to and below the securing surfacewhen the caster assembly is coupled to the vertical support member. 14.The caster assembly of claim 1, wherein: the first member comprises afirst sub-member disposed beneath the vertical support member when thecaster assembly is coupled to the vertical support member.
 15. Thecaster assembly of claim 14, wherein the first sub-member comprises afirst surface perpendicular to the first sub-member and extending awayfrom the first member and the second member.
 16. The caster assembly ofclaim 14, wherein the first sub-member comprises a “U” shaped memberdisposed to extend around a bottom of the vertical support member.
 17. Ashelf assembly, comprising: a plurality of vertical support members; asecuring member, releasably coupled to at least one of the plurality ofvertical support members, the securing member having a downfacingsurface perpendicular to the vertical support members, the downfacingsurface configured to bear at least a portion of the weight of the shelfassembly when the shelf assembly is lifted by a pallet disposed betweenthe vertical support members and below the downfacing surface; and aplurality of casters, each caster having a wheel and removably coupledto the bottom of each of the plurality of vertical support members. 18.A method of assembling a wheeled shelf assembly having a plurality ofvertical support members and a plurality of support members comprising aweight bearing member, comprising the steps of: removably affixing acaster assembly to a bottom end of each of the vertical support members,each of the casters comprising: a first member, disposed to accept awheel on a first end of the first member; a caster weight bearing membercoupled to the first member, the caster weight bearing memberperpendicular to the vertical support members; removably affixing asecuring member to at least one of the vertical support members, thesecuring member comprising a horizontal weight bearing member having adownfacing surface disposed proximate and above the caster weightbearing member, the horizontal weight bearing member also configured tobear at least a portion of the weight of the shelf assembly when theshelf assembly is lifted by a pallet disposed between the verticalsupport members and below the downfacing surface.
 19. The method ofclaim 18, wherein: the step of affixing the caster to the verticalsupport member comprises the steps of: inserting tabs disposed on thecaster into apertures disposed in the vertical support member, andapplying force to the caster in a direction towards a longitudinalcenter of the vertical support member; the step of affixing the securingmember to the vertical support member comprises the steps of: insertingtabs disposed on the securing member into apertures disposed in thevertical support member, and applying force to the securing membertowards the affixed caster.
 20. A caster assembly, comprising: a firstmember, the first member having one or more first member featuresdisposed to be removably coupled to a corresponding one or more firstmatching features of a vertical support member of a shelf assembly; asecond member, the second member having one or more second memberfeatures disposed to be removably coupled to a corresponding one or moresecond matching features of the vertical support member; and a sleeve,coupled to the first member and the second member, the sleeve foraccepting a shaft coupled to a wheel.